EP2321178B1 - Method for making a nacelle de-icing element - Google Patents

Method for making a nacelle de-icing element Download PDF

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Publication number
EP2321178B1
EP2321178B1 EP09737016.7A EP09737016A EP2321178B1 EP 2321178 B1 EP2321178 B1 EP 2321178B1 EP 09737016 A EP09737016 A EP 09737016A EP 2321178 B1 EP2321178 B1 EP 2321178B1
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EP
European Patent Office
Prior art keywords
network
support
nacelle
completion
icing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP09737016.7A
Other languages
German (de)
French (fr)
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EP2321178A1 (en
Inventor
Laurent Valleroy
Marc Gerome
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Nacelles SAS
Original Assignee
Aircelle SA
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Publication date
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Publication of EP2321178A1 publication Critical patent/EP2321178A1/en
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Publication of EP2321178B1 publication Critical patent/EP2321178B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D33/00—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for
    • B64D33/02—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/04—Air intakes for gas-turbine plants or jet-propulsion plants
    • F02C7/047—Heating to prevent icing
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • H05B3/267—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an organic material, e.g. plastic
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/28—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material
    • H05B3/286—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor embedded in insulating material the insulating material being an organic material, e.g. plastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D33/00—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for
    • B64D33/02—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes
    • B64D2033/0233—Arrangements in aircraft of power plant parts or auxiliaries not otherwise provided for of combustion air intakes comprising de-icing means
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2201/00—Metals
    • F05C2201/04—Heavy metals
    • F05C2201/0433—Iron group; Ferrous alloys, e.g. steel
    • F05C2201/0466—Nickel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/10—Metals, alloys or intermetallic compounds
    • F05D2300/17—Alloys
    • F05D2300/172—Copper alloys
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/603—Composites; e.g. fibre-reinforced
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2300/00—Materials; Properties thereof
    • F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
    • F05D2300/614—Fibres or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
    • Y10T156/109—Embedding of laminae within face of additional laminae

Definitions

  • the invention relates to a method for manufacturing an element comprising a deicing device.
  • the invention also relates to a turbojet engine nacelle comprising such an element.
  • An aircraft is propelled by one or more propulsion units each comprising a turbojet engine housed in a tubular nacelle.
  • Each propulsion unit is attached to an aircraft by a mast located under a wing or at the fuselage.
  • a nacelle generally has a structure comprising an air inlet upstream of the engine and a median section adapted to surround a fan of the turbojet engine, a downstream section housing thrust reversal means and adapted to surround the combustion chamber of the turbojet engine.
  • the nacelle is terminated by an ejection nozzle whose output is located downstream of the turbojet engine.
  • the air intake comprises, on the one hand, an inlet lip adapted to allow optimal capture to the turbojet of the air necessary to supply the blower and the internal compressors of the turbojet engine, and other on the other hand, a downstream structure, to which the lip is attached, intended to properly channel the air towards the blades of the fan.
  • the assembly is attached upstream of a blower housing belonging to the upstream section of the nacelle.
  • ice may form on the nacelle in various locations including the outer surface of the air intake lip.
  • the presence of ice or frost changes the aerodynamic properties of the air intake and disturbs the flow of air to the blower.
  • a solution for deicing or deicing the nacelle, in particular the outer surface of the air inlet lip, consists in preventing ice from forming on the wall by heating the latter by a heating electric resistance.
  • the heating resistor is typically mounted on or in the outer wall of an element to be de-iced, for example in the case where the heating resistors are in the form of sheets.
  • the manufacture of such an element is difficult to achieve because of the geometry of the wall.
  • the deicing device must not interfering with other performances performed by the nacelle element such as absorption noises generated by the operation of the turbojet engine.
  • the heating resistor must not interfere with the holes of the latter, for example by plugging these holes.
  • the electrical resistance is in the form of sheets and in the case where the acoustic holes have been made first, the placement of said sheets around the acoustic holes is difficult. In the case where the resistive sheets are placed first, the perforation of said sheets to obtain acoustic holes damages the acoustic resistance.
  • the heating resistors of the prior art has an integration on composite supports generally performed manually. As a result, the manufacture of these resistors is long and complex.
  • the manufacturing tolerances and the location of the heating resistances are variable according to the operators.
  • An object of the present invention is therefore to provide an air intake lip does not have the aforementioned drawbacks.
  • the method according to the invention advantageously makes it possible to simply and efficiently produce an element that can be de-iced.
  • the method of the invention has a number of steps limiting the manual operations.
  • the method of the invention advantageously makes it possible to precisely position the acoustic holes with respect to the conductive elements.
  • the insulation distance of the heating resistors and their power supply with said holes is advantageously respected which guarantees a good operation of the de-icing assembly.
  • the placement of the resistance with respect to the acoustic holes is more accurate with the method of the invention as well as no drilling of said resistor. 'is necessary.
  • the subject of the invention is a nacelle for a turbojet comprising an element obtained according to the method of the invention.
  • the element of the invention is an air intake lip which is an element of the nacelle particularly sensitive to the deposition of frost or ice.
  • a nacelle 1 As represented in figure 1 , a nacelle 1 according to the invention comprises an air inlet lip 2, a median structure 3 surrounding a fan 4 of a turbojet engine 5 and a downstream assembly 6.
  • the downstream assembly 6 consists of an internal structure fixed 7 (IFS) surrounding the upstream portion of the turbojet engine 5, a fixed external structure 8 (OFS) and a movable cowl 9 comprising thrust reversal means.
  • the element according to the invention may be an air intake lip which is an element of the nacelle which is particularly sensitive to the deposition of ice and frost (see figure 2 ). It is also possible to use the method according to the invention to manufacture any surface to be de-iced, such as helicopter or aircraft ducts, or the exposed areas of a turbojet engine such as the blades of blowing, the arms crossing the flow of water. like the OGV, ...
  • This method is applicable to a composite structure that is monolithic, autoraidie or sandwich in order to meet the constraints of thermal efficiency, structural strength, ...
  • the air inlet lip 2 of the invention comprises an inner skin 12 mounted on a deicing assembly 13 adapted to deice and deglaze the air inlet lip 2.
  • the inner skin 12 may comprise in certain areas an acoustic panel to absorb noise pollution due to the operation of the turbojet engine 5.
  • the acoustic panel comprises a honeycomb structure 14 sandwiched between a composite layer 15 pierced with multiple acoustic holes and a solid outer layer 16, c that is, not having a multitude of acoustic holes.
  • the composite layer 15 overcomes the deicing assembly 13.
  • the deicing assembly 13 may also be coated on the other side with a surface coating 17 to protect the latter from erosion and possible impacts.
  • the deicing assembly 13, if necessary the surface coating 17, is in contact with the cold air flow 18 which is not the case of the inner skin 12.
  • the inner skin 12 is a non-acoustic structuring skin, namely having a honeycomb structure without acoustic holes. It is also possible that the inner skin 12 is not structuring but only a non-acoustic composite layer.
  • the air inlet lip 2 is obtained according to the method of the invention.
  • the method of the invention provides in a simple manner an effective deicing assembly.
  • the de-icing assembly can be advantageously manufactured before or simultaneously with the implementation of the air intake lip 2.
  • the method of the invention offers a possibility of relatively varied network geometry. Therefore, it is possible to precisely choose the shape of the pattern of the network so as to have an optimal defrost according to the need.
  • the method of the invention ensures precise positioning of the heating resistor network. Such precision of the network position is advantageous when the deicing assembly is intended to be fixed on an acoustic structure.
  • an array of heating resistors 20 is manufactured on a support 24 by a photolithography process.
  • the support 24 is substantially plane, which makes it possible to further simplify the implementation of the method of the invention.
  • a conductive layer 22 is fixed on the support 24 by any means known to those skilled in the art.
  • the fixing is performed by an adhesive.
  • the heating resistors 20 comprise a metal or alloy with a resistivity of between 0.0002 ⁇ .mm and 0.002 ⁇ .mm, preferably between 0.00024 ⁇ .mm and 0.002 ⁇ .mm, or even between 0.0004 ⁇ .mm and 0.001 ⁇ .mm.
  • the heating resistors 20 generate a heating power of between 1 kW.m -2 and 50 kW.m -2 , in particular between 4 kW.m -2 and 20 kW.m -2 .
  • Such heating power advantageously allows to take off any frost or ice formed on the air inlet surface 2 by using the minimum amount of electrical energy or to prevent the formation of such frost or ice.
  • the alloy of the heating resistors 20 is chosen from alloys of copper and nickel, for example constantan (CuNi44).
  • the support 24 is preferably manufactured from glass fibers, epoxy resin or any electrically insulating film such as a thermoplastic film.
  • the epoxy resin 914® may be mentioned as epoxy resin.
  • a photosensitive layer 26 comprising at least one photosensitive element is mounted on the conductive layer 22.
  • a photosensitive element mention may be made of negative resins such as SU-8® resin. , for which the ultraviolet radiation causes a polymerization of the exposed areas, giving these areas a particular resistance to the developing solvent while the non-insolated parts disappear selectively in the developing solvent. Mention may also be made of resins of the resin type AZ 9260®, S1818® and SJR 5740®, for which the ultraviolet radiation produces a chemical transformation of the macromolecules, which leads to an increased solubility of the exposed zones in the developer, or to the invertible resins. type AZ 5214® and T109XR® which have the property of changing polarity following a so-called inversion annealing step.
  • a mask 30 is applied above the assembly consisting of the support 24, the conductive layer 22 and the photosensitive layer 26.
  • the mask comprises the pattern 33 of the resistance network.
  • the assembly is firstly insulated by any means 32 adapted and known to those skilled in the art.
  • any means 32 adapted and known to those skilled in the art.
  • the photosensitive layer 26 protected by the pattern 33 drawn on the mask 30 is not obscured by the UV radiation which makes it possible to print the pattern on said layer 26.
  • the unprotected photosensitive layer 26 is, for its part, obscured.
  • the duration of the insolation is variable and depends on the pattern that one wants to engrave. Typically, the duration of insolation is about 2 min 30s. Indeed, the duration of the exposure of the photosensitive layer 26 must be long enough for the pattern 33 to be printed on said photosensitive layer 26 but short enough to prevent the UV rays from crossing the entire surface of the mask 30, thus erasing any reason.
  • the unprotected photosensitive layer 26 is then removed by any suitable developer product known to those skilled in the art.
  • the remaining photosensitive layer 26 reproduces the pattern of the desired grating.
  • the remaining photosensitive layer 26 is then removed by any suitable chemical and known to those skilled in the art so that the conductive layer 22 reveals the pattern of the network 20 of heating resistors (see figure 7 ).
  • the heating resistances of the conductive layer 22 are generally sensitive to oxidation. As a result, they may need to be protected.
  • a power supply network (not shown) is manufactured on the opposite face 40 of the heating resistor network.
  • the supply network may be made by any suitable means known to those skilled in the art, in particular by a photolithography process, as presented above.
  • the supply network is preferably connected to the network of heating resistors 20 via connection means (not shown) passing through the support 24.
  • the feed network typically comprises a metal or alloy whose resistivity is as low as possible in order to minimize line losses.
  • the resistivity of the metal or alloy is equal to about 1.7 ⁇ .cm.
  • the supply network is not intended to generate heat but to conduct the current to the network 20 of heating resistors.
  • metal mention may be made of copper.
  • step B of the process of the invention said network 20 obtained at the end of step A is inserted or even encapsulated in folds of composite materials 52 and 50 (see FIG. figure 8 ).
  • the support 24 may be substituted for one of the plies of composite materials 52 or 50.
  • a ply of composite material 50 or 52 is applied. on the network 20 obtained at the end of step A.
  • the network 20 will thus be inserted between the support 24 on one side and a fold of composite material 50 or 52 on the opposite side.
  • each fold 50 and 52 comprises a material such as fiberglass associated with a thermoset resin (Epoxy) or thermoplastic (PEEK).
  • Epoxy thermoset resin
  • PEEK thermoplastic
  • Folds in contact with or near electrical networks must electrically isolate them from other electrically conductive components or plies such as the epoxy carbon commonly used for stress-transmitting layers.
  • Fixing the grating obtained at the end of step A on the ply or folds of composite materials 50, 52 may be reinforced by any means known to those skilled in the art, in particular by gluing.
  • a surface coating 17 is applied, which makes it possible to respond to shocks, aerodynamic stresses, erosion and lightning protection.
  • the surface coating 17 is for example a wire mesh or a layer of carbon fiber.
  • the fixing of the surface coating 17 on the deicing assembly 13 is done by any means known and adapted to those skilled in the art, in particular by gluing.
  • step C of the process of the invention the inner skin 12 is applied to the deicing assembly 13 thus obtained.
  • Fixing the inner skin 12 on the deicing assembly 13 is carried out by any means known to those skilled in the art, in particular by gluing.
  • the method of the invention comprises a step B1 between step B and C in which the deicing assembly obtained at the end of step B is pierced by piercing means so as to obtain acoustic holes of diameter preferably between 0.2 mm and 2.5 mm, or even between 0.3 and 2 mm.
  • piercing means to have a hole accuracy of the order of 0.05 mm with respect to the network of heating resistors 20.
  • drilling means there may be mentioned a drill, a laser and a jet of water.
  • the piercing means it is advantageous for the piercing means to be recalented by means of a radio-type camera on a reference pattern engraved during the formation of the network of heating resistors 20.
  • the deicing assembly 13 and the composite layer 15 of the internal skin 12 are pierced by the piercing means.
  • the composite layer 15 of the inner skin 12 is made and pierced prior to step C.
  • the outer skin 15 is pierced prior to its installation on the deicing assembly 13.
  • the surface of the deicing assembly 13 is cut out so that the maximum distance emax between the deicing assembly 13 and the inner skin 12, generally of non-developable shape, is of the order of 1.7 mm which allows a good conformation of the defrost assembly 13, especially during the cooking of the latter.
  • the deicing assembly 13 initially made substantially flat matches the curvatures of the air intake lip 2.
  • the inlet lip 2 obtained by the method according to the invention is integrated with the nacelle 1 of an aircraft.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Structures Of Non-Positive Displacement Pumps (AREA)
  • Surface Heating Bodies (AREA)
  • Resistance Heating (AREA)

Description

L'invention concerne un procédé de fabrication d'un élément comportant un dispositif de dégivrage.The invention relates to a method for manufacturing an element comprising a deicing device.

L'invention concerne également une nacelle pour turboréacteur comprenant un tel élément.The invention also relates to a turbojet engine nacelle comprising such an element.

Un avion est propulsé par un ou plusieurs ensembles propulsifs comprenant chacun un turboréacteur logé dans une nacelle tubulaire. Chaque ensemble propulsif est rattaché à un aéronef par un mât situé sous une aile ou au niveau du fuselage.An aircraft is propelled by one or more propulsion units each comprising a turbojet engine housed in a tubular nacelle. Each propulsion unit is attached to an aircraft by a mast located under a wing or at the fuselage.

Une nacelle présente généralement une structure comprenant une entrée d'air en amont du moteur et une section médiane apte à entourer une soufflante du turboréacteur, une section aval abritant des moyens d'inversion de poussée et apte à entourer la chambre de combustion du turboréacteur. La nacelle est terminée par une tuyère d'éjection dont la sortie est située en aval du turboréacteur.A nacelle generally has a structure comprising an air inlet upstream of the engine and a median section adapted to surround a fan of the turbojet engine, a downstream section housing thrust reversal means and adapted to surround the combustion chamber of the turbojet engine. The nacelle is terminated by an ejection nozzle whose output is located downstream of the turbojet engine.

L'entrée d'air comprend, d'une part, une lèvre d'entrée adaptée pour permettre la captation optimale vers le turboréacteur de l'air nécessaire à l'alimentation de la soufflante et des compresseurs internes du turboréacteur, et d'autre part, une structure aval, sur laquelle est rapportée la lèvre, destinée à canaliser convenablement l'air vers les aubes de la soufflante. L'ensemble est rattaché en amont d'un carter de la soufflante appartenant à la section amont de la nacelle.The air intake comprises, on the one hand, an inlet lip adapted to allow optimal capture to the turbojet of the air necessary to supply the blower and the internal compressors of the turbojet engine, and other on the other hand, a downstream structure, to which the lip is attached, intended to properly channel the air towards the blades of the fan. The assembly is attached upstream of a blower housing belonging to the upstream section of the nacelle.

En vol, selon les conditions de température et d'humidité, de la glace peut se former sur la nacelle en divers endroits dont la surface externe de la lèvre d'entrée d'air. La présence de glace ou de givre modifie les propriétés aérodynamiques de l'entrée d'air et perturbe l'acheminement de l'air vers la soufflante.In flight, depending on the temperature and humidity conditions, ice may form on the nacelle in various locations including the outer surface of the air intake lip. The presence of ice or frost changes the aerodynamic properties of the air intake and disturbs the flow of air to the blower.

Une solution pour dégivrer ou déglacer la nacelle, notamment la surface externe de la lèvre d'entrée d'air, consiste à éviter que de la glace ne se forme sur la paroi en réchauffant ces dernières par une résistance électrique chauffante. La résistance chauffante est montée typiquement sur ou dans la paroi externe d'un élément à dégivrer, par exemple dans le cas où les résistances chauffantes sont sous forme de feuilles.A solution for deicing or deicing the nacelle, in particular the outer surface of the air inlet lip, consists in preventing ice from forming on the wall by heating the latter by a heating electric resistance. The heating resistor is typically mounted on or in the outer wall of an element to be de-iced, for example in the case where the heating resistors are in the form of sheets.

Un exemple d'un tel dispositif de dégivrage est illustré dans le document EP-A2-1826119 .An example of such a deicing device is illustrated in the document EP-A2-1826119 .

Or, la fabrication d'un tel élément est difficile à réaliser à cause de la géométrie de la paroi. En effet, le dispositif de dégivrage ne doit pas interférer avec d'autres performances réalisées par l'élément de la nacelle telle que l' absorption les bruits générés par le fonctionnement du turboréacteur. En particulier, la résistance chauffante ne doit pas interférer avec les trous de ce dernier, par exemple en bouchant ces trous.However, the manufacture of such an element is difficult to achieve because of the geometry of the wall. Indeed, the deicing device must not interfering with other performances performed by the nacelle element such as absorption noises generated by the operation of the turbojet engine. In particular, the heating resistor must not interfere with the holes of the latter, for example by plugging these holes.

Dans le cas où la résistance électrique est sous la forme de feuilles et dans le cas où les trous acoustiques ont été réalisés en premier, le placement desdites feuilles autour des trous acoustiques est difficile. Dans le cas où les feuilles résistives sont placées en premier, la perforation desdites feuilles pour obtenir des trous acoustiques endommage la résistance acoustique.In the case where the electrical resistance is in the form of sheets and in the case where the acoustic holes have been made first, the placement of said sheets around the acoustic holes is difficult. In the case where the resistive sheets are placed first, the perforation of said sheets to obtain acoustic holes damages the acoustic resistance.

De plus, les résistances chauffantes de l'art antérieur présente une intégration sur des supports composites effectuée généralement de manière manuelle. De ce fait, la fabrication de ces résistances est longue et complexe.In addition, the heating resistors of the prior art has an integration on composite supports generally performed manually. As a result, the manufacture of these resistors is long and complex.

En outre, les tolérances de fabrication et la localisation des résistances chauffantes sont variables selon les opérateurs.In addition, the manufacturing tolerances and the location of the heating resistances are variable according to the operators.

Un but de la présente invention est donc de fournir une lèvre d'entrée d'air ne présentant pas les inconvénients précités.An object of the present invention is therefore to provide an air intake lip does not have the aforementioned drawbacks.

A cet effet, selon un premier aspect, l'invention a pour objet un procédé de fabrication d'une lèvre d'entrée d'air d'une nacelle comprenant les étapes où :

  • A. on fabrique un réseau de résistances chauffantes sur un support par un procédé de photolithographie ;
  • B. on applique un pli de matériaux composites sur ledit réseau obtenu à l'issue de l'étape A pour obtenir un ensemble de dégivrage ;
  • B1. on perce l'ensemble de dégivrage obtenu à l'issue de l'étape B et une peau interne, comportant une peau composite sur laquelle est montée une structure en nid d'abeille, par des moyens de perçage de sorte à obtenir des trous acoustiques ;
  • C. on applique une peau interne, destinée à être placée à l'intérieur d'une lèvre d'entrée d'air de la nacelle, sur l'ensemble de dégivrage obtenu à l'issue de l'étape B1.
For this purpose, according to a first aspect, the invention relates to a method of manufacturing an air intake lip of a nacelle comprising the steps where:
  • A. a network of heating resistors is manufactured on a support by a photolithography process;
  • B. applying a fold of composite materials to said network obtained at the end of step A to obtain a deicing assembly;
  • B1. the deicing assembly obtained at the end of step B is pierced and an internal skin, comprising a composite skin on which a honeycomb structure is mounted, by piercing means so as to obtain acoustic holes; ;
  • C. an internal skin, intended to be placed inside an air inlet lip of the nacelle, is applied to the deicing assembly obtained at the end of step B1.

Le procédé selon l'invention permet avantageusement de réaliser simplement et efficacement un élément susceptible d'être dégivré.The method according to the invention advantageously makes it possible to simply and efficiently produce an element that can be de-iced.

De plus, le procédé de l'invention présente un nombre d'étapes limitant les opérations manuelles.In addition, the method of the invention has a number of steps limiting the manual operations.

Le procédé de l'invention permet de manière avantageuse de positionner précisément les trous acoustiques par rapport aux éléments conducteurs. Ainsi, la distance d'isolement des résistances chauffantes et de leur alimentation électrique avec lesdits trous est avantageusement respectée ce qui garantit un bon fonctionnement de l'ensemble de dégivrage.The method of the invention advantageously makes it possible to precisely position the acoustic holes with respect to the conductive elements. Thus, the insulation distance of the heating resistors and their power supply with said holes is advantageously respected which guarantees a good operation of the de-icing assembly.

Contrairement au cas où la résistance électrique est sous forme de feuilles juxtaposées les unes à côté des autres, le placement de la résistance par rapport aux trous acoustiques est plus précis avec le procédé de l'invention de même qu'aucun perçage de ladite résistance n'est nécessaire.In contrast to the case where the electrical resistance is in the form of sheets juxtaposed next to each other, the placement of the resistance with respect to the acoustic holes is more accurate with the method of the invention as well as no drilling of said resistor. 'is necessary.

Selon d'autres caractéristiques de l'invention, la structure de l'invention comporte l'une ou plusieurs des caractéristiques optionnelles suivantes considérées seules ou selon toutes les combinaisons possibles :

  • l'étape B est une étape dans laquelle on insère dans des plis de matériaux composites ledit réseau obtenu à l'issue de l'étape A ;
  • les trous acoustiques obtenus ont un diamètre compris entre 0,2 mm et 2,5 mm, ce qui assure une bonne absorption acoustique et une bonne tenue structurale ;
  • préalablement à l'étape B, on fabrique un réseau d'alimentation électrique sur la face opposée de la face du support comportant le réseau de résistances chauffantes ce qui permet d'alimenter en électricité le réseau de résistances chauffantes ;
  • le réseau d'alimentation est relié au réseau de résistances chauffantes par l'intermédiaire de moyens de connexion passant au travers du support ce qui permet d'éviter l'ajout de fils électriques ;
  • le réseau d'alimentation comprend un métal ou un alliage, dont la résistivité à température ambiante est égale à environ 1,7 µΩ.cm ;
  • les résistances chauffantes comprennent un métal ou alliage de résistivité comprise entre 0,000 24 Ω.mm et 0,002 Ω.mm, ce qui permet d'obtenir un bon dégivrage de l'élément de l'invention en employant le minimum d'énergie électrique ;
  • l'alliage des résistances chauffantes est choisi parmi les alliages de cuivre et de nickel ;
  • le support est fabriqué à partir de fibres de verre, de résine epoxy, ou de film isolant thermoplastique ;
  • chaque pli comprend un matériau type fibre de verre associée à une résine thermodure ou thermoplastique;
  • pendant l'étape A, le support est sensiblement plat ;
  • préalablement à l'étape C, on découpe la surface de l'ensemble de dégivrage de sorte que l'écart maximal entre l'ensemble de dégivrage et la peau interne soit de l'ordre de 1,7 mm ce qui permet une bonne conformation de l'ensemble de dégivrage ;
  • on applique à l'issue de l'étape B ou C un revêtement de surface sur l'ensemble de dégivrage ce qui permet de répondre aux contraintes aérodynamiques, d'érosion et de protection contre la foudre.
According to other features of the invention, the structure of the invention comprises one or more of the following optional features considered alone or according to all the possible combinations:
  • step B is a step in which is inserted into folds of composite materials said network obtained at the end of step A;
  • the acoustic holes obtained have a diameter of between 0.2 mm and 2.5 mm, which ensures good acoustic absorption and good structural strength;
  • prior to step B, a power supply network is manufactured on the opposite face of the support surface comprising the heating resistor network, which makes it possible to supply electricity to the heating resistor network;
  • the supply network is connected to the heating resistor network via connection means passing through the support which avoids the addition of electrical son;
  • the feed network comprises a metal or alloy whose resistivity at ambient temperature is equal to about 1.7 μΩ.cm;
  • the heating resistors comprise a metal or alloy with a resistivity of between 0.000 24 Ω.mm and 0.002 Ω.mm, which makes it possible to obtain a good deicing of the element of the invention by employing the minimum of electrical energy;
  • the alloy of the heating resistors is chosen from alloys of copper and nickel;
  • the support is made from glass fibers, epoxy resin, or thermoplastic insulating film;
  • each ply comprises a fiberglass type material associated with a thermoset or thermoplastic resin;
  • during step A, the support is substantially flat;
  • prior to step C, the surface of the deicing assembly is cut so that the maximum distance between the deicing assembly and the internal skin is of the order of 1.7 mm, which allows a good conformation defrost assembly;
  • at the end of step B or C, a surface coating is applied to the deicing assembly, which makes it possible to respond to aerodynamic, erosion and lightning protection stresses.

Selon un deuxième aspect, l'invention a pour objet une nacelle pour turboréacteur comportant un élément obtenu selon le procédé de l'invention. De manière préférentielle, l'élément de l'invention est une lèvre d'entrée d'air qui est un élément de la nacelle particulièrement sensible au dépôt de givre ou de glace.According to a second aspect, the subject of the invention is a nacelle for a turbojet comprising an element obtained according to the method of the invention. Preferably, the element of the invention is an air intake lip which is an element of the nacelle particularly sensitive to the deposition of frost or ice.

L'invention sera davantage comprise à la lecture de la description non limitative qui va suivre, faite en référence aux figures ci-annexées.

  • la figure 1 est une coupe schématique transversale d'une nacelle de l'invention entourant un turboréacteur ;
  • la figure 2 est une coupe schématique transversale d'un exemple d'élément de l'invention ;
  • la figure 3 à 7 est une coupe transversale partielle d'un ensemble de dégivrage obtenu selon le procédé de l'invention;
  • la figure 8 est une coupe transversale d'un panneau acoustique d'un élément obtenu selon le procédé de l'invention.
The invention will be better understood on reading the nonlimiting description which follows, with reference to the appended figures.
  • the figure 1 is a schematic cross section of a nacelle of the invention surrounding a turbojet engine;
  • the figure 2 is a schematic cross section of an exemplary element of the invention;
  • the figure 3 to 7 is a partial cross section of a deicing assembly obtained according to the method of the invention;
  • the figure 8 is a cross section of an acoustic panel of an element obtained according to the method of the invention.

Comme représenté à la figure 1, une nacelle 1 selon l'invention comprend une lèvre d'entrée d'air 2, une structure médiane 3 entourant une soufflante 4 d'un turboréacteur 5 et un ensemble aval 6. L'ensemble aval 6 est constitué d'une structure interne fixe 7 (IFS) entourant la partie amont du turboréacteur 5, d'une structure externe fixe 8 (OFS) et d'un capot mobile 9 comportant des moyens d'inversion de poussée.As represented in figure 1 , a nacelle 1 according to the invention comprises an air inlet lip 2, a median structure 3 surrounding a fan 4 of a turbojet engine 5 and a downstream assembly 6. The downstream assembly 6 consists of an internal structure fixed 7 (IFS) surrounding the upstream portion of the turbojet engine 5, a fixed external structure 8 (OFS) and a movable cowl 9 comprising thrust reversal means.

L'élément selon l'invention peut être une lèvre d'entrée d'air qui est un élément de la nacelle particulièrement sensible au dépôt de glace et de givre (voir figure 2). Il est également possible d'employer le procédé selon l'invention pour fabriquer toute surface devant être dégivrée, telles que des conduits pour hélicoptère ou aéronef, ou les zones exposées d'un turboréacteur comme les aubes de souflantes, les bras traversant le flux d'air comme les OGV, ...The element according to the invention may be an air intake lip which is an element of the nacelle which is particularly sensitive to the deposition of ice and frost (see figure 2 ). It is also possible to use the method according to the invention to manufacture any surface to be de-iced, such as helicopter or aircraft ducts, or the exposed areas of a turbojet engine such as the blades of blowing, the arms crossing the flow of water. like the OGV, ...

Ce procédé est applicable à une structure composite quel soit monolithique, autoraidie ou sandwich afin de répondre aux contraintes de rendement thermique, de tenue structurale, ...This method is applicable to a composite structure that is monolithic, autoraidie or sandwich in order to meet the constraints of thermal efficiency, structural strength, ...

Dans le mode de réalisation représenté à la figure 2, la lèvre d'entrée d'air 2 de l'invention comporte une peau interne 12 montée sur un ensemble de dégivrage 13 apte à dégivrer et déglacer la lèvre d'entrée d'air 2. La peau interne 12 peut comporter dans certaines zones un panneau acoustique afin d'absorber les nuisances sonores dues au fonctionnement du turboréacteur 5. Le panneau acoustique comporte une structure en nid d'abeille 14 prise en sandwich entre une couche composite 15 percée de multiples trous acoustiques et une couche externe 16 pleine, c'est-à-dire ne présentant pas une multitude de trous acoustiques. La couche composite 15 surmonte l'ensemble de dégivrage 13.In the embodiment shown at figure 2 , the air inlet lip 2 of the invention comprises an inner skin 12 mounted on a deicing assembly 13 adapted to deice and deglaze the air inlet lip 2. The inner skin 12 may comprise in certain areas an acoustic panel to absorb noise pollution due to the operation of the turbojet engine 5. The acoustic panel comprises a honeycomb structure 14 sandwiched between a composite layer 15 pierced with multiple acoustic holes and a solid outer layer 16, c that is, not having a multitude of acoustic holes. The composite layer 15 overcomes the deicing assembly 13.

L'ensemble de dégivrage 13 peut également être revêtu sur l'autre face d'un revêtement de surface 17 permettant de protéger ce dernier de l'érosion et d'éventuels impacts. L'ensemble de dégivrage 13, le cas échéant le revêtement de surface 17, est en contact avec le flux d'air froid 18 ce qui n'est pas le cas de la peau interne 12.The deicing assembly 13 may also be coated on the other side with a surface coating 17 to protect the latter from erosion and possible impacts. The deicing assembly 13, if necessary the surface coating 17, is in contact with the cold air flow 18 which is not the case of the inner skin 12.

Dans d'autres zones de la lèvre d'entrée d'air 2 de l'invention, la peau interne 12 est une peau structurante non acoustique, à savoir comportant une structure en nid d'abeille sans trous acoustiques. Il est également possible que la peau interne 12 ne soit pas structurante mais uniquement une couche composite non acoustique.In other areas of the air intake lip 2 of the invention, the inner skin 12 is a non-acoustic structuring skin, namely having a honeycomb structure without acoustic holes. It is also possible that the inner skin 12 is not structuring but only a non-acoustic composite layer.

La lèvre d'entrée d'air 2 est obtenue selon le procédé de l'invention.The air inlet lip 2 is obtained according to the method of the invention.

Le procédé de l'invention fournit de manière simple un ensemble de dégivrage efficace. L'ensemble de dégivrage peut être avantageusement fabriqué antérieurement ou simultanément à la mise en oeuvre de la lèvre d'entrée d'air 2.The method of the invention provides in a simple manner an effective deicing assembly. The de-icing assembly can be advantageously manufactured before or simultaneously with the implementation of the air intake lip 2.

Le procédé de l'invention offre une possibilité de géométrie de réseau assez varié. De ce fait, il est possible de choisir de manière précise la forme du motif du réseau de sorte à avoir un dégivrage optimal en fonction du besoin.The method of the invention offers a possibility of relatively varied network geometry. Therefore, it is possible to precisely choose the shape of the pattern of the network so as to have an optimal defrost according to the need.

Par ailleurs, le procédé de l'invention assure un positionnement précis du réseau de résistances chauffantes. Une telle précision de la position du réseau s'avère avantageuse lorsque l'ensemble de dégivrage est destiné à être fixé sur une structure acoustique.Moreover, the method of the invention ensures precise positioning of the heating resistor network. Such precision of the network position is advantageous when the deicing assembly is intended to be fixed on an acoustic structure.

Comme représenté sur les figures 3 à 7, dans l'étape A, on fabrique un réseau de résistances chauffantes 20 sur un support 24 par un procédé de photolithographie. Selon un mode de réalisation préférentiel, le support 24 est sensiblement plan ce qui permet de simplifier encore davantage la mise en oeuvre du procédé de l'invention. Selon une autre variante, il est également possible d'appliquer le procédé de photolithographie sur un support présentant la forme de la lèvre d'entrée d'air 2.As shown on Figures 3 to 7 in step A, an array of heating resistors 20 is manufactured on a support 24 by a photolithography process. According to a preferred embodiment, the support 24 is substantially plane, which makes it possible to further simplify the implementation of the method of the invention. According to another variant, it is also possible to apply the photolithography process on a support having the shape of the air intake lip 2.

Pour fabriquer le réseau de résistances chauffantes, on fixe une couche conductrice 22 sur le support 24 par tout moyen connu de l'homme du métier. A titre d'exemple, la fixation est effectuée par une colle.To manufacture the heating resistances network, a conductive layer 22 is fixed on the support 24 by any means known to those skilled in the art. For example, the fixing is performed by an adhesive.

Les résistances chauffantes 20 comprennent un métal ou un alliage de résistivité comprise entre 0,0002 Ω.mm et 0,002 Ω.mm, de préférence entre 0,00024 Ω.mm et 0,002 Ω.mm, voire entre 0,0004 Ω.mm et 0,001 Ω.mm. De ce fait, les résistances chauffantes 20 génèrent une puisance de chauffage comprise entre 1 kW.m-2 et 50 kW.m-2, notamment entre 4 kW.m-2 et 20 kW.m-2. Une telle puissance de chauffage permet avantageusement de décoller tout givre ou glace formé sur la surface d'entrée d'air 2 en employant le minimum d'énergie électrique ou d'empêcher la formation d'un tel givre ou d'une telle glace.The heating resistors 20 comprise a metal or alloy with a resistivity of between 0.0002 Ω.mm and 0.002 Ω.mm, preferably between 0.00024 Ω.mm and 0.002 Ω.mm, or even between 0.0004 Ω.mm and 0.001 Ω.mm. As a result, the heating resistors 20 generate a heating power of between 1 kW.m -2 and 50 kW.m -2 , in particular between 4 kW.m -2 and 20 kW.m -2 . Such heating power advantageously allows to take off any frost or ice formed on the air inlet surface 2 by using the minimum amount of electrical energy or to prevent the formation of such frost or ice.

En particulier, l'alliage des résistances chauffantes 20 est choisi parmi des alliages de cuivre et de nickel, par exemple le constantan (CuNi44).In particular, the alloy of the heating resistors 20 is chosen from alloys of copper and nickel, for example constantan (CuNi44).

Le support 24 est fabriqué préférentiellement à partir de fibres de verre, de résine epoxy ou de tout film isolant électriquement tel qu'un film thermoplastique. A titre d'exemple, on peut citer comme résine epoxy la résine epoxy 914®.The support 24 is preferably manufactured from glass fibers, epoxy resin or any electrically insulating film such as a thermoplastic film. By way of example, the epoxy resin 914® may be mentioned as epoxy resin.

Sur la couche comportant les résistances chauffantes, une couche photosensible 26 comprenant au moins un élément photosensible est monté sur la couche conductrice 22. A tire d'exemple d'élément photosensible, on peut citer les résines négatives telle que la résine SU-8®, pour lesquelles le rayonnement ultraviolet entraîne une polymérisation des zones exposées, conférant à ces zones une tenue particulière au solvant de révélation alors que les parties non insolées disparaissent sélectivement dans le solvant de révélation. On peut également citer les résines positives de type résines AZ 9260®, S1818® et SJR 5740®, pour lesquelles le rayonnement ultraviolet produit une transformation chimique des macromolécules ce qui entraîne une solubilité accrue des zones exposées dans le révélateur, ou encore les résines inversibles de type AZ 5214® et T109XR® qui présentent la propriété de changer de polarité suite à une étape de recuit, dite d'inversion.On the layer comprising the heating resistors, a photosensitive layer 26 comprising at least one photosensitive element is mounted on the conductive layer 22. As an example of a photosensitive element, mention may be made of negative resins such as SU-8® resin. , for which the ultraviolet radiation causes a polymerization of the exposed areas, giving these areas a particular resistance to the developing solvent while the non-insolated parts disappear selectively in the developing solvent. Mention may also be made of resins of the resin type AZ 9260®, S1818® and SJR 5740®, for which the ultraviolet radiation produces a chemical transformation of the macromolecules, which leads to an increased solubility of the exposed zones in the developer, or to the invertible resins. type AZ 5214® and T109XR® which have the property of changing polarity following a so-called inversion annealing step.

Comme représenté sur la figure 4, on applique un masque 30 au-dessus de l'ensemble constitué par le support 24, la couche conductrice 22 et la couche photosensible 26. Le masque comporte le motif 33 du réseau de résistance.As shown on the figure 4 a mask 30 is applied above the assembly consisting of the support 24, the conductive layer 22 and the photosensitive layer 26. The mask comprises the pattern 33 of the resistance network.

Afin d'obtenir le réseau de résistances chauffantes désiré, on insole tout d'abord l'ensemble par tout moyen 32 adapté et connu par l'homme du métier. A titre d'exemple, on peut citer une lampe UV.In order to obtain the desired network of heating resistances, the assembly is firstly insulated by any means 32 adapted and known to those skilled in the art. By way of example, mention may be made of a UV lamp.

La couche photosensible 26 protégée par le motif 33 dessiné sur le masque 30 n'est pas obscurcie par le rayonnement UV ce qui permet d'imprimer le motif sur ladite couche 26. La couche photosensible 26 non protégée est, quant à elle, obscurcie.The photosensitive layer 26 protected by the pattern 33 drawn on the mask 30 is not obscured by the UV radiation which makes it possible to print the pattern on said layer 26. The unprotected photosensitive layer 26 is, for its part, obscured.

La durée de l'insolation est variable et dépend du motif que l'on veut graver. Typiquement, la durée d'insolation est d'environ 2 min 30s. En effet, la durée de l'exposition de la couche photosensible 26 doit être suffisamment longue pour que le motif 33 soit imprimé sur ladite couche photosensible 26 mais suffisamment courte pour éviter que les rayons UV ne traversent toute la superficie du masque 30, effaçant alors tout motif.The duration of the insolation is variable and depends on the pattern that one wants to engrave. Typically, the duration of insolation is about 2 min 30s. Indeed, the duration of the exposure of the photosensitive layer 26 must be long enough for the pattern 33 to be printed on said photosensitive layer 26 but short enough to prevent the UV rays from crossing the entire surface of the mask 30, thus erasing any reason.

La couche photosensible 26 non protégée est ensuite éliminée par tout produit révélateur adapté et connu de l'homme du métier.The unprotected photosensitive layer 26 is then removed by any suitable developer product known to those skilled in the art.

De ce fait, comme représenté à la figure 5, la couche photosensible restante 26 reproduit le motif du réseau désiré.As a result, as shown in figure 5 the remaining photosensitive layer 26 reproduces the pattern of the desired grating.

On applique ensuite tout produit chimique adapté et connu de l'homme du métier afin d'éliminer la partie 34 de la couche conductrice non située en-dessous de la couche photosensible 26 restante. Ainsi, comme représenté à la figure 6, il ne reste que la partie de la couche conductrice 22 située en-dessous du motif formé par la couche photosensible 26.Any suitable chemical known to those skilled in the art is then applied to remove the portion 34 of the conductive layer not below the remaining photosensitive layer 26. Thus, as represented in figure 6 only the portion of the conductive layer 22 lying below the pattern formed by the photosensitive layer 26 remains.

La couche photosensible 26 restante est alors éliminée par tout produit chimique adapté et connu de l'homme du métier de sorte que la couche conductrice 22 révèle le motif du réseau 20 de résistances chauffantes (voir figure 7).The remaining photosensitive layer 26 is then removed by any suitable chemical and known to those skilled in the art so that the conductive layer 22 reveals the pattern of the network 20 of heating resistors (see figure 7 ).

Les résistances chauffantes de la couche conductrice 22 sont généralement sensibles à l'oxydation. De ce fait, elles peuvent nécessiterr d'être protégées. Ainsi, dans une variante de réalisation du procédé,, il est possible de prévoir une étape dans laquelle on oxyde le réseau 20 par dépôt d'une couche d'oxyde, par exemple par électrolyse.The heating resistances of the conductive layer 22 are generally sensitive to oxidation. As a result, they may need to be protected. Thus, in an alternative embodiment of the method, it is possible to provide a step in which the network 20 is oxidized by deposition of an oxide layer, for example by electrolysis.

Selon un mode de réalisation préféré non représenté, préalablement à l'étape B, on fabrique un réseau d'alimentation électrique (non représenté) sur la face opposée 40 du réseau de résistances chauffantes.According to a preferred embodiment not shown, prior to step B, a power supply network (not shown) is manufactured on the opposite face 40 of the heating resistor network.

Le réseau d'alimentation peut être réalisé par tout moyen approprié connu de l'homme du métier, en particulier par un procédé de photolithographie, comme présenté ci-dessus.The supply network may be made by any suitable means known to those skilled in the art, in particular by a photolithography process, as presented above.

Le réseau d'alimentation est de préférence relié au réseau de résistances chauffantes 20 par l'intermédiaire de moyens de connexion (non représentés) passant au travers du support 24.The supply network is preferably connected to the network of heating resistors 20 via connection means (not shown) passing through the support 24.

Le réseau d'alimentation comprend typiquement un métal ou un alliage dont la résistivité est la plus faible possible afin de minimiser les pertes en ligne. De manière préférentielle, la résistivité du métal ou de l'alliage est égale à environ 1,7 µΩ.cm. Le réseau d'alimentation n'est pas destiné à dégager de la chaleur mais à conduire le courant jusqu'au réseau 20 de résistances chauffantes. Comme exemple de métal, on peut citer le cuivre.The feed network typically comprises a metal or alloy whose resistivity is as low as possible in order to minimize line losses. Preferably, the resistivity of the metal or alloy is equal to about 1.7 μΩ.cm. The supply network is not intended to generate heat but to conduct the current to the network 20 of heating resistors. As an example of metal, mention may be made of copper.

Dans l'étape B du procédé de l'invention, on insère voire on encapsule ledit réseau 20 obtenu à l'issue de l'étape A dans des plis de matériaux composites 52 et 50 (voir figure 8).In step B of the process of the invention, said network 20 obtained at the end of step A is inserted or even encapsulated in folds of composite materials 52 and 50 (see FIG. figure 8 ).

Dans une variante de réalisation de l'étape B, le support 24 peut se substituer à l'un des plis de matériaux composites 52 ou 50. Dans ce cas, dans l'étape B, on applique un pli de matériau composite 50 ou 52 sur le réseau 20 obtenu à l'issue de l'étape A.In an alternative embodiment of step B, the support 24 may be substituted for one of the plies of composite materials 52 or 50. In this case, in step B, a ply of composite material 50 or 52 is applied. on the network 20 obtained at the end of step A.

Le réseau 20 sera ainsi inséré entre le support 24 d'un côté et un pli de matériau composite 50 ou 52 du côté opposé.The network 20 will thus be inserted between the support 24 on one side and a fold of composite material 50 or 52 on the opposite side.

Préférentiellement, chaque pli 50 et 52 comprend un matériau comme de la fibre de verre associée à une résine thermodure (Epoxy) ou thermoplastique (PEEK). Les plis au contact ou proches des réseaux éléctriques doivent les isoler électriquement d'autres composants ou de plis électriquement conducteurs comme le carbone epoxy couramment utilisé pour couches 15 transmettant des efforts.Preferably, each fold 50 and 52 comprises a material such as fiberglass associated with a thermoset resin (Epoxy) or thermoplastic (PEEK). Folds in contact with or near electrical networks must electrically isolate them from other electrically conductive components or plies such as the epoxy carbon commonly used for stress-transmitting layers.

La fixation du réseau 20 obtenu à l'issue de l'étape A sur le ou les plis de matériaux composites 50,52 peut être renforcée par tout moyen connu de l'homme du métier, notamment par collage.Fixing the grating obtained at the end of step A on the ply or folds of composite materials 50, 52 may be reinforced by any means known to those skilled in the art, in particular by gluing.

Selon un mode de réalisation préféré, on applique à l'issue de l'étape B ou C un revêtement surface 17 ce qui permet de répondre aux chocs, aux contraintes aérodynamiques, d'érosion et de protection contre la foudre. Le revêtement de surface 17 est par exemple un treillis métallique ou encore une couche de fibre de carbone. La fixation du revêtement de surface 17 sur l'ensemble de dégivrage 13 se fait par tout moyen connu et adapté de l'homme du métier, notamment par collage.According to a preferred embodiment, at the end of step B or C, a surface coating 17 is applied, which makes it possible to respond to shocks, aerodynamic stresses, erosion and lightning protection. The surface coating 17 is for example a wire mesh or a layer of carbon fiber. The fixing of the surface coating 17 on the deicing assembly 13 is done by any means known and adapted to those skilled in the art, in particular by gluing.

Dans l'étape C du procédé de l'invention, on applique la peau interne 12 sur l'ensemble de dégivrage 13 ainsi obtenu. La fixation de la peau interne 12 sur l'ensemble de dégivrage 13 est réalisée par tout moyen connu de l'homme du métier, notamment par collage.In step C of the process of the invention, the inner skin 12 is applied to the deicing assembly 13 thus obtained. Fixing the inner skin 12 on the deicing assembly 13 is carried out by any means known to those skilled in the art, in particular by gluing.

Le procédé de l'invention comporte une étape B1 entre l'étape B et C dans laquelle on perce l'ensemble de dégivrage obtenu à l'issue de l'étape B par des moyens de perçage de sorte à obtenir des trous acoustiques de diamètre préférentiellement compris entre 0,2 mm et 2,5 mm, voire entre 0,3 et 2 mm. Avantageusement, on utilise des moyens de perçage permettant d'avoir une précision des trous de l'ordre de 0,05 mm par rapport au réseau de résistances chauffantes 20. A titre d'exemple de moyens de perçage, on peut citer une perceuse, un laser et un jet d'eau.The method of the invention comprises a step B1 between step B and C in which the deicing assembly obtained at the end of step B is pierced by piercing means so as to obtain acoustic holes of diameter preferably between 0.2 mm and 2.5 mm, or even between 0.3 and 2 mm. Advantageously, using drilling means to have a hole accuracy of the order of 0.05 mm with respect to the network of heating resistors 20. By way of example of drilling means, there may be mentioned a drill, a laser and a jet of water.

Selon un mode de réalisation, il est intéressant que les moyens de perçage se recalent grâce à une caméra de type radio sur une mire de référence gravée lors de la formation du réseau de résistances chauffantes 20. Une distance comprise entre 0,2 mm et 10 mm, voire entre 0,5 mm et 1 mm, peut être prévue entre les trous acoustiques et les branches du réseau 20, de sorte de garantir une isolation électrique entre les résistances et l'extérieur.According to one embodiment, it is advantageous for the piercing means to be recalented by means of a radio-type camera on a reference pattern engraved during the formation of the network of heating resistors 20. A distance of between 0.2 mm and 10 mm. mm, or even between 0.5 mm and 1 mm, can be provided between the acoustic holes and the branches of the network 20, so as to ensure electrical insulation between the resistors and the outside.

Ainsi, il est possible d'obtenir à la fois un ensemble de dégivrage 13 efficace pour dégivrer la lèvre d'entée d'air 2 et également une meilleure performance acoustique.Thus, it is possible to obtain both an effective deicing assembly 13 for de-icing the air intake lip 2 and also a better acoustic performance.

Selon le procédé de l'invention, on perce l'ensemble de dégivrage 13 et la couche composite 15 de la peau interne 12 par les moyens de perçage.According to the method of the invention, the deicing assembly 13 and the composite layer 15 of the internal skin 12 are pierced by the piercing means.

La couche composite 15 de la peau interne 12 est réalisée et percée préalablement à l'étape C. Autrement dit, la peau externe 15 est percée préalablement à sa pose sur l'ensemble de dégivrage 13.The composite layer 15 of the inner skin 12 is made and pierced prior to step C. In other words, the outer skin 15 is pierced prior to its installation on the deicing assembly 13.

Selon un mode de réalisation préféré, dans le cas où le support 24 est sensiblement plan, préalablement à l'étape C, on découpe la surface de l'ensemble de dégivrage 13 de sorte que l'écart maximal emax entre l'ensemble de dégivrage 13 et la peau interne 12 , généralement de forme non développable, soit de l'ordre de 1,7 mm ce qui permet une bonne conformation de l'ensemble de dégivrage 13, notamment pendant la cuisson de ce dernier. De ce fait, l'ensemble de dégivrage 13 réalisé initialement sensiblement à plat épouse les courbures de la lèvre d'entrée d'air 2.According to a preferred embodiment, in the case where the support 24 is substantially flat, prior to step C, the surface of the deicing assembly 13 is cut out so that the maximum distance emax between the deicing assembly 13 and the inner skin 12, generally of non-developable shape, is of the order of 1.7 mm which allows a good conformation of the defrost assembly 13, especially during the cooking of the latter. As a result, the deicing assembly 13 initially made substantially flat matches the curvatures of the air intake lip 2.

Lorsque la lèvre d'entrée d'air 2 est fabriquée selon le procédé de l'invention, ladite lèvre 2 est soumise à une cuisson dont les conditions sont connues de l'homme du métier afin de garantir une bonne cohésion de l'ensemble.When the air inlet lip 2 is manufactured according to the method of the invention, said lip 2 is subjected to a firing whose conditions are known to those skilled in the art to ensure good cohesion of the assembly.

La lèvre d'entrée 2 obtenue par le procédé selon l'invention est intégrée à la nacelle 1 d'un aéronef.The inlet lip 2 obtained by the method according to the invention is integrated with the nacelle 1 of an aircraft.

Claims (14)

  1. A method for manufacturing an air inlet lip (2) of a nacelle (1) comprising the steps of :
    A. manufacturing a heating resistor network (20) on a support (24) by means of a photolithography method ;
    B. applying a fold (50, 52) of composite materials on the network (20), obtained on completion of step A, in order to obtain a de-icing set (13) ;
    B1. piercing the de-icing set (13), obtained on completion of step B and an inner skin (12), including a composite skin on which a honeycomb structure is mounted, by piercing means so as to obtain acoustic holes ;
    C. applying the inner skin (12), intended to be placed inside an air inlet lip (2) of the nacelle (1), on the de-icing set (13) obtained on completion of step B1.
  2. The method according to the preceding claim, characterized in that step B is a step during which said network (20), obtained in step A, is inserted within folds (50, 52) of composite materials.
  3. The method according to claim 1, characterized in that the obtained acoustic holes have a diameter comprised between 0.2 mm and 2.5 mm.
  4. The method according to any one of the preceding claims, characterized in that, prior to step B, an electric power supply network is manufactured on the face (40) opposite to the face of the support (24) including the heating resistor network (20).
  5. The method according to the preceding claim, characterized in that the power supply network is connected to the heating resistor network (20) via connecting means passing through the support (24).
  6. The method according to claim 4 or 5, characterized in that the power supply network comprises a metal or an alloy the resistivity of which at ambient temperature is equal to about 1.7 µΩ.cm.
  7. The method according to any one of the preceding claims, characterized in that the heating resistors comprise a metal or an alloy the resistivity of which is comprised between 0.00024 Ω.mm and 0.002 Ω.mm.
  8. The method according to the preceding claim, characterized in that the alloy of the heating resistors (20) is selected among the alloys of copper and nickel.
  9. The method according to any one of the preceding claims, characterized in that the support (24) is manufactured from fiberglass, an epoxy resin, or a thermoplastic insulating film.
  10. The method according to any one of the preceding claims, characterized in that, during step A, the support (24) is substantially flat.
  11. The method according to any one of the preceding claims, characterized in that each fold (50, 52) comprises a fiberglass-type material associated to a thermosetting or thermoplastic resin.
  12. The method according to any one of the preceding claims, characterized in that, prior to step C, the surface of the de-icing set (13) is sliced so that the maximum gap (emax) between the de-icing set (13) and the inner skin (12) is in the range of 1.7 mm.
  13. The method according to any one of the preceding claims, characterized in that, on completion of step B or C, a surface coating (17) is applied over the de-icing set (13).
  14. A nacelle (1) for a turbojet engine including an air inlet lip (2) obtained according to the method of any one of the preceding claims.
EP09737016.7A 2008-09-03 2009-08-14 Method for making a nacelle de-icing element Active EP2321178B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0804824A FR2935357B1 (en) 2008-09-03 2008-09-03 METHOD FOR MANUFACTURING A NACELLE ELEMENT
PCT/FR2009/001008 WO2010026304A1 (en) 2008-09-03 2009-08-14 Method for making a nacelle de-icing element

Publications (2)

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EP2321178A1 EP2321178A1 (en) 2011-05-18
EP2321178B1 true EP2321178B1 (en) 2016-04-27

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US (1) US9027884B2 (en)
EP (1) EP2321178B1 (en)
CN (1) CN102143888B (en)
BR (1) BRPI0917881A2 (en)
CA (1) CA2733427A1 (en)
FR (1) FR2935357B1 (en)
RU (1) RU2500581C2 (en)
WO (1) WO2010026304A1 (en)

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Publication number Publication date
CN102143888A (en) 2011-08-03
WO2010026304A1 (en) 2010-03-11
FR2935357B1 (en) 2010-08-27
US20110162340A1 (en) 2011-07-07
RU2011111993A (en) 2012-10-10
US9027884B2 (en) 2015-05-12
FR2935357A1 (en) 2010-03-05
CA2733427A1 (en) 2010-03-11
EP2321178A1 (en) 2011-05-18
RU2500581C2 (en) 2013-12-10
BRPI0917881A2 (en) 2015-11-24
CN102143888B (en) 2013-12-25

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